Method for disposing a laser blocking material on the interior of an airfoil

ABSTRACT

A method for disposing laser blocking material  52  on the interior of an airfoil  10 , such as a rotor blade or stator vane, includes shear thinning the material. Various steps are developed which promote decreases in viscosity of the blocking material. In one detailed embodiment, the material is passed through an injection molding machine  54  to provide shear thinning.

This application claims benefit from U.S. Provisional Application Ser.No. 60/109,176 filed on Nov. 20, 1998.

CROSS-REFERENCE TO RELATED APPLICATION

This application relates to commonly owned U.S. applications: U.S.patent application Ser. No. 09/162,832 now U.S. Pat. No. 5,914,060entitled “Method of Laser Drilling an Airfoil”, by Jeffrey D. Flis etal.; U.S. patent application 09/162,614 now U.S. Pat. No. 5,928,534entitled method for “Reducing Void Volumes in Cavities for LaserDrilling”, by Jeffrey D. Flis et al.; Ser. No. 09/213,591 entitled“Method and Material for Processing a Component for Laser Machining”, byFoster Philip Lamm et al.; Ser. No. 09/213,592 entitled “Tool forDisposing Laser Blocking Material in an Airfoil”, by Christopher P.Jordan et al.; Ser. No. 09/213,580 now U.S. Pat. No. 6,177,038 entitled“Method for Orienting an Airfoil for Processing and for Forming a Maskfor the Airfoil”, by Stanley J. Funk et al.; and Ser. No. 09/213,593entitled “Fixture for Disposing a Laser Blocking Material in anAirfoil”, by Gordon M. Reed et al.

DESCRIPTION

Technical Field

This invention relates to a method for disposing laser blocking materialprior to drilling cooling air holes with a laser into an airfoil havinginternal passages for cooling air. More particularly, the methodincludes steps for disposing laser blocking material in the cavity forblocking a laser beam from striking the interior as the hole is drilledto the internal passage through a wall of the airfoil.

BACKGROUND OF THE INVENTION

Airfoils for gas turbine engines are disposed in a flow path for workingmedium gases. Examples of such airfoils are turbine blades and turbinevanes. The airfoils are bathed in hot gases as the gases are flowedthrough the engine. Cooling air is flowed though passages on theinterior of the airfoil under operative conditions to keep thetemperature of the airfoil, such as a turbine vane or turbine blade,within acceptable limits.

In addition, the airfoil may have cooling air holes extending from theinterior to the exterior of the airfoil. The cooling air holes are smalland may have diameters that are in a range of eleven to seventeen mils(0.011-0.017 inches). The holes are drilled in pre-determined patternsand are contoured to ensure adequate cooling of the airfoil.

The cooling air holes duct cooling air from passages on the interior ofthe airfoil through the hot walls to the exterior. The cooling airprovides transpiration cooling as the air passes through the wall and,after the air is discharged from the airfoil, provides film cooling witha film of air on the exterior. The film of cooling air provides abarrier between the airfoil and the hot, working medium gasses.

One way to drill the holes uses a laser to direct a beam of coherentenergy at the exterior of the airfoil. The intense radiation from thelaser beam burns through the wall of the airfoil, leaving behind a holewhich provides a satisfactory conduit for cooling air. As the laser beampenetrates through the airfoil wall into an interior cavity, the laserbeam may strike adjacent structure on the other side of the cavitycausing unacceptable damage to the airfoil. Accordingly, blockingmaterial may be disposed in the cavity to block the laser beam fromstriking walls bounding the cavity after the beam penetrates through theairfoil wall.

One approach is to leave disposed within the airfoil the ceramic castingcore around which the blade is poured during the manufacturing process.The ceramic core provides a suitable blocking material. The ceramic coreis subsequently removed by well known leaching techniques. This approachis described in U.S. Pat. No. 5,222,617 entitled “Drilling TurbineBlades” issued to Gregore, Griffith and Stroud. However, the presence ofthe core after casting prevents initial inspection of the interior ofthe airfoil. The ceramic material may also be difficult to remove oncethe cooling air holes are drilled. In addition, the core is notavailable for use with the airfoil during repair processes which mayrequire redrilling of the cooling air holes.

Another example of a blocking material is wax or a wax-like material.The material is melted so that it may easily flow into interiorpassages, such as the leading edge passage of the airfoil. Thetemperature of the molten material above its melting point, may exceedtwo hundred and fifty degrees Fahrenheit (250°). The molten material maybe poured by hand or injected into the cavity or may even be sprayed orpainted on the surface to be protected. However, the molten material mayseverely scald personnel working with the material. Moreover, theoperation is time consuming if such material is poured by hand into theairfoil. In addition, the wax may extend between two closely adjacentcooling air holes. The wax adjacent the first hole, which blocks thelaser beam as the second hole is drilled, may melt as the first hole isdrilled by the laser beam. This causes a void to form in the wax. As aresult, the energy from the laser beam at the second hole may not besufficiently dissipated by the wax as it passes through the portion ofthe passage having the void. Damage may occur to the airfoil as thesecond hole is drilled because the beam, after it penetrates through thewall at the second hole, may strike the interior wall of the airfoil.

One wax-like blocking material which uses an additive to avoid formingvoids is discussed in U.S. Pat. No. 5,049,722, issued to Corfe andStroud, entitled “Laser Barrier Material And Method Of Laser Drilling.”In Corfe, a PTFE (polytetrafluoroethylene) wax-like material is disposedin a wax base. The PTFE helps avoid the formation of voids. Disposingsuch material on the interior of a leading edge passage is particularlydifficult for some airfoils. Often the leading edge passage has noconnection during fabrication with the exterior of the airfoil. It is ablind or dead end passage prior to the drilling operation except forsmall impingement holes which place the passage in gas communicationwith an adjacent passage. The adjacent passage also has an opening forreceiving cooling air which is flowed to the leading edge passage.Accordingly, personnel must carefully pour the molten material in theinlet opening and manipulate the airfoil to avoid bubbles in thematerial in the leading edge passage.

Still another approach is to use a masking agent, such as an epoxyresin, which is disposed in the airfoil in a fluid state. The epoxyresin is disposed in the airfoil by simply pouring the resin into theairfoil. The epoxy resin is at room temperature and poses no scaldinghazard to personnel. The epoxy resin is further processed to harden thefluid and cause it to become a more solid material similar to the PTFEwax mentioned in U.S. Pat. No. 5,049,722. However, the resin isrelatively viscous compared to molten wax and has difficulty in flowingthrough small connecting passages on the interior of the airfoil.

It may be particularly difficult in some airfoils to dispose suchmaterial on the interior of a leading edge passage. Often the leadingedge passage has no connection during fabrication with the exterior ofthe airfoil. It is a blind or dead end passage prior to the drillingoperation except for small impingement holes which place the passage ingas communication with an adjacent passage. The adjacent passage alsohas an opening for receiving cooling air which is flowed to the leadingedge passage. Accordingly, personnel must carefully pour the moltenmaterial in the inlet opening and manipulate the airfoil to avoidbubbles in the material in the leading edge passage and manipulate theairfoil to avoid the formation of voids. The material does have theadvantage of being easily removed by heating the material to atemperature that vaporizes the material.

Another approach is to use a thixotropic medium that comprises materialsfor dispersing laser light. This approach is discussed in U.S. Pat. No.4,873,414 issued to Ma and Pinder entitled “Laser Drilling ofComponents”. A particular advantage of this medium is that it emitslight when contacted by the laser light. Monitoring the light reflectedfrom the component may allow detection of the laser beam as the laserbeam breaks through the second surface allowing a feedback control todetermine whether or not the laser beam has drilled a through hole. Inaddition, the viscosity of the medium may be decreased by forcing themedium through a nozzle to lower the viscosity of the medium so that themedium flows readily over an inner surface of the component. Thethixotropic medium may be removed by contacting the medium with aflushing agent which requires both additional manipulation of thecomponent and the active flowing of additional material into thecomponent.

Another approach is shown in U.S. Pat. No. 5,140,127 entitled “LaserBarrier Material” issued to Stroud and Corse. This approach uses aninjectable barrier material which is a composition selected from thegroup consisting of a first copolymer of tetrafluoroethylene andhexfluoropropylene and a second copolymer having apolytetrafluoroethylene backbone and a least one fluorinated alkoxy sidegroup. The material is poured or injected into the interior of thecomponent. The material is subsequently steamed out of the componentafter filling and laser drilling the hollow turbine blades. It is likelypossible to remove the material in a more passive fashion such as byheating the material to a very high temperature to vaporize thematerial. However, the products of such combustion will contain fluorineatoms and may result in forming harmful fluids which must be scrubbedfrom the products of combustion before releasing the products ofcombustion into the atmosphere.

Another approach is shown in U.S. Pat. No. 5,767,482 entitled “LaserBarrier Material and Method” issued to Turner. Turner uses finelydivided crystalline material such as sodium chloride (salt), or othermetal salts which are thermally stable and possess a high melting point.Salt may be introduced into the interior of a component by pouring or bymaking it a paste with water and injecting it. The salt is removed bywashing the component with water.

The above art notwithstanding, scientists and engineers working underthe direction of Applicants Assignee have sought to develop materials,methods, and devices for disposing laser blocking material on theinterior of airfoils which are suitable for use in mass productionoperations and are relatively easy to remove without forming noxiousfluids or without performing several time consuming operations.

SUMMARY OF INVENTION

This invention is in part predicated on the recognition that certainpolymers when used to block laser beams, provide a significant advantagein mass production operations and that certain tooling and fixtures maybe used with such material or other materials in mass productionoperations to speed the filling of components such as airfoils. Inaddition, certain polymers have an advantageous effect on the magnitudeof forces transmitted from the blocking material in small passages tothe thin walls of the airfoil which forces result from disposing thematerial in the airfoil and removing the material from the airfoil. Inaddition, these materials adapt themselves well to rapid processingduring the removal operation of the material by heating the materials totheir fairly low melting point to allow the melting material topartially escape and then vaporizing the material at a highertemperature in a way that does not form harmful products of combustion.

According to the present invention, a method for disposing laserblocking material on the interior of an airfoil includes shear thinninga laser blocking material having a shear thinning characteristic that isgreater than zero and pressurizing the laser blocking material to anextent that causes additional shear thinning as the material flowsthrough the interior of the airfoil.

In accordance with one aspect of the present invention, the methodincludes disposing a polyolefin material in a chamber and transferringenergy to the material until the temperature of the material is greaterthan three hundred degrees Fahrenheit (300° F.) prior to flowing thematerial into the interior of the airfoil.

In accordance with the present invention, the step of transferringenergy to the laser blocking material includes passing the materialthrough an injection molding machine and further includes transferringheat to the material and shearing the material to transfer energy to thematerial in the injection molding machine.

In accordance with another embodiment of the present invention, the stepof forming the charge of laser blocking material includes forming acharge which is slightly larger than the internal volume of the airfoil.

A primary feature of the present invention is forming the charge oflaser blocking material using a material that has a shear thinningcharacteristic that is greater than zero. Another feature of the presentinvention is the step of passing the laser blocking material underpressure through orifices to cause shear thinning of the material.Another feature of the present invention is the step of passing thelaser blocking material through an injection molding machine whichcauses shear thinning of the material as the material proceeds to thenozzle of the injection molding machine.

A primary advantage of the present invention is the speed at which laserblocking material can be disposed on interior of the airfoil whichresults from supplying the laser blocking material in a way that causesthe viscosity of the material to suddenly decrease as a result of shearthinning. Another advantage is the integrity of the filled airfoil whichresults from avoiding large pressure differentials in small cavities inthe airfoil of a size that could rupture the airfoil by shear thinningthe laser blocking material as it passes through the small cavities.Another advantage of the present invention is the processing speed whichresults from decreasing the cool down time for the airfoil by processinglaser blocking material at temperatures less than five hundred degreesFahrenheit (500° F.) and is made possible by decreasing the viscosity ofthe laser blocking material through shear thinning to an extent thatavoids the need to decrease viscosity by heating the laser blockingmaterial to temperatures elevated above five hundred degrees Fahrenheit(500° F.) which make the airfoil difficult to handle for a period oftime.

The foregoing and other features and advantages of the present inventionwill become more apparent in light of the following detailed descriptionof the invention and as discussed and illustrated in the accompanyingdrawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is perspective view in full of a component, such as an airfoil;of a tool for disposing laser blocking material in the component; and,in phantom, of a portion of a source of laser blocking material, such asan injection molding machine.

FIG. 1A is a side elevation, cross sectional view of the airfoil shownin FIG. 1.

FIG. 1B is a cross-sectional view of the airfoil shown in FIG. 1A takenalong the lines 1B—1B of FIG. 1A.

FIG. 2 is a view from above of FIG. 1 with portions of the tool andinjection molding machine either broken away for clarity or shown inphantom.

FIG. 3 is an exploded view of part of a nozzle for the injection moldingmachine and part of the tool shown in FIG. 1, which has a pair of maskmembers.

FIG. 3A is alternate embodiment of a portion of the tool shown in FIG.3A showing mask members formed in part of fairly rigid material whichengages the platform of the airfoil shown in FIG. 3.

FIG. 4 is perspective view from below of a sprue plate shown in FIG. 1and FIG. 3.

FIG. 5 is a perspective view from below of an alternate embodiment ofthe sprue plate shown in FIG. 4 having a recess for a seal, and showingin exploded fashion, a seal member which fits in the recess.

FIG. 6 is a perspective view of the tool shown in FIG. 1 installed on anapparatus for orienting the airfoil with respect to a source of laserblocking material and shows a sprue plate and a sprue plate holder whichhas been modified slightly to engage the apparatus.

FIG. 7 is a graphical representation of the shear thinningcharacteristic for a linear polyethylene polymer and shows viscosity inPascal Seconds as a function of shear rate in reciprocal seconds.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 is a partial perspective view of a component, as represented byan airfoil 10 for a gas turbine engine. FIG. 1 also shows a tool 12 fordisposing a laser blocking material on the interior of the component.The tool has a cavity 13 in which airfoils are disposed repetitively as,one after another, the airfoils are filled. Although the airfoil shownis a rotor blade the term “airfoil” includes other components havingflow directing surfaces such as stator vanes.

FIG. 1A is a side elevation cross sectional view of the rotor blade 10during manufacture. The rotor blade has a first end, as represented bythe root 14, a platform 16, and a second end, as represented by the tip18. The airfoil has an aerodynamic leading edge 22 which extendsspanwise. An aerodynamic trailing edge 24 is spaced chordwise from theaerodynamic leading edge. The airfoil has a plurality of cavities orpassages for cooling air as represented by the leading edge passage 26and passages 28, 30, 32, 34 which extend through the root of the rotorblade. The passages 28, 30, 32, and 34 extend into the interior of therotor blade and often extend in serpentine fashion as represented by thepassage 32.

FIG. 1B is a cross sectional view taken chordwise along the line 1B—1Bof FIG. 1A. The airfoil has flow directing surfaces, as represented bythe suction surface side or sidewall 42 and the pressure surface side orsidewall 44. Each of these surfaces extend rearwardly from the leadingedge to the trailing edge and extend spanwise between the platform 16and the tip 18.

A plurality of internal impingement holes, as represented by the hole48, connect the leading edge passage 26 in the leading edge region withthe supply passage 28 for cooling air. The impingement holes are ofsmall size and have a hydraulic diameter that is typically less thanforty (40) mils (that is, D_(h)=4Ai/P=0.040 inches, where A is the areaof the hole and P is the perimeter of the hole). In some applications,the holes may have a hydraulic diameter that is less than thirty (30)mils. A plurality of film cooling holes adjacent the leading edge 22, asrepresented by the holes 46, extend from the impingement passage 26 inthe leading edge region to the exterior of the rotor blade.

As shown in FIG. 1B, one way of forming the film cooling hole 46 is todrill the hole with a laser beam, as represented by the laser beam L,from the exterior of the airfoil to the leading edge passage 26. Asshown in FIG. 1B and in schematic fashion in FIG. 1A, a laser blockingmaterial 52 is disposed in the leading edge passage on a portion of thecomponent for attenuating the intensity of the laser beam. The laserblocking material ensures that the laser beam does not injure structurethat faces the cooling air hole as the laser beam breaks through thewall of the rotor blade during the drilling process.

As shown in FIG. 1, means for supplying the blocking material underpressure, as represented by part of an injection-molding machine 54, isin flow communication with the tool 12. Alternate equivalent machinesinclude any machine capable of being a source of pressurized laserblocking material to the airfoil such as transfer molding machines andplastic extrusion machines.

The tool 12 includes a fixture 56 for engaging the rotor blade andfilling the rotor blade with laser blocking material. The term “filling”means to dispose or supply the material and includes partially fillingor completely filling the blade. The fixture includes a base 58, sprueplate 62 and sprue plate holder 64. A passage 65 for supplying the laserblocking material extends through the sprue plate and sprue plateholder.

The injection molding machine has a table 66 for receiving the tool anda housing 68 that has a nozzle 70 as shown in FIG. 3 and FIG. 3A. Thehousing is movable in the direction M with respect to the tool 12 andcan exert a predetermined force on the tool and on the rotor blade. Thehousing has a chamber 72 for receiving a charge 74 of laser blockingmaterial 52 (shown in schematic fashion). The volume of the charge isslightly larger than the internal volume of the interior of the airfoilwhich is receiving the laser blocking material.

The chamber 72 receives the laser blocking material from a passage (notshown) which has disposed therein screw means (not shown) for forcingthe laser blocking material into the chamber. A piston 75 is disposed inthe chamber for driving the laser blocking material in passage 65through the housing to the sprue plate. One satisfactory machine forthis purpose is the Model 70 Injection Molding Machine available fromthe Mini-Jector Machinery Corp., Newbury, Ohio. Another machine whichhas proven satisfactory is the Toyo Plastar TI-90G2 injection moldingmachine available from the Hitachi Group through Toyo of America, 16Chapin, Pinebrook N.J. 07053.

As shown in FIG. 1, the sprue plate holder 64 of the tool 12 isintegrally joined, such as by bolts (not shown), to the housing 68 ofthe injection molding machine 54. The sprue plate holder has a dove tailslot 76. The sprue plate 62 slidably engages the sprue plate holderthrough the dovetail slot and has tapered edges 77 which cooperate withthe dovetail slot to retain the sprue plate. The sprue plate has part ofthe passage 65 for receiving the laser blocking material. The passageplaces the chamber 72 of the injection molding machine in flowcommunication with the passages 28, 30, 32, 34 which extend through theroot 14 of the turbine blade 10.

The table is adjustable with respect to the housing 68 of the injectionmolding machine 54. The tool base 58 is located in predetermined fashionwith respect to the table 66. The base is adapted by locating dowels orlocating pins (not shown) for this purpose to precisely engage the tableat the same location each time that the fixture is installed on thetable. Accordingly, the tool base is adjustable through the table withrespect to the housing.

The tool includes a mask 78. The mask has a pair of mask members, asrepresented by the first mask member 82 and the second mask member 84.The mask members each have a surface, as represented by the firstsurface 86 of the first mask member and the second surface 88 of thesecond mask member. The surfaces each conform to the exterior of theairfoil. The mask members are formed of elastomeric material such asroom temperature vulcanized (RTV) rubber. One satisfactory elastomer ismaterial is RTV 668 Elastomeric material available from the GeneralElectric Company, Waterford, N.Y.

The tool further includes a pair of opposed jaws as represented by thefirst jaw 92 and the second jaw 94. Each jaw engages an associated maskmember 82, 84 for urging the mask member into a faying relationship withthe airfoil 10. For example, the second jaw 94 engages the second maskmember 84. Because the second jaw is fixed to the base of the tool, thesecond jaw provides a reference surface 96 with respect to both thehousing 68 and to the second mask member 84. The housing positions thesprue plate. Accordingly, the second jaw with its chordwise facingreference surface provides, in combination with the sprue plate and thesprue plate holder, a precise way of aligning the rotor blade with theinjection molding machine during the filling operation.

The jaws 92, 94 are capable of relative movement with respect to each isother. As shown by the phantom lines in FIG. 1, the first jaw is movablewith respect to the second jaw from the closed position shown in full toan open position shown in phantom. The second jaw 94 has a pair ofguides for such movement disposed on each side of the jaw, asrepresented by the guides 98 and the guides 102. The first jaw 92 has afirst guide rail 104 which slidably engages the first pair of guides 98.The first jaw has a second guide rail 106 which slidably engages thesecond pair of guides 102. Alternatively, such relative movement mightbe accomplished by moving both jaws. As mentioned above, the second jawprovides the reference surface 96 for locating the mask 78 with respectto the housing of the injection molding machine. This feature might bereplicated provided the second jaw returns precisely to its closedposition.

The tool includes means for moving the jaws from the open position tothe closed position, as represented by the arm 108 and lever 112mechanism shown in FIG. 1. The arm is pivoted about a pivot point 113.As the arm pivots to the open, moved position, the lever pulls the firstjaw 92 and the first mask member 82 away from the rotor blade 10enabling the operator to rapidly remove or insert a rotor blade into thesecond masking member 84. Other devices for the means for moving the jawmight be actuated by electrical, electrical, pneumatic or hydraulicarrangements or mechanical actuators such as chains, pulleys, orsprings.

FIG. 2 is a view from above of FIG. 1 with portions of the tool 12 andthe injection molding machine broken 54 away for clarity. FIG. 2 showsthe relationship of the rotor blade 10 to the sprue plate 62 and to thepassage 65 extending spanwise through the sprue plate. The passageadapts the sprue plate to receive the pressurized blocking material fromthe nozzle 70 of the injection molding machine. The sprue plate has afirst side 114 having a first spanwise facing surface 116. The surface116 faces spanwise away from the rotor blade in the operative conditionin a first direction along a spanwise axis S. As shown in FIG. 2, thespanwise axis S is the stacking line of the chordwise sections of therotor blade. The first surface 116 adapts the sprue plate to engage thenozzle (shown in FIG. 3) and form a seal about the passage 65 forreceiving the pressurized blocking material.

The passage 65 has a narrow portion 118 for discharging the pressurizedblocking material into the rotor blade 10. The narrow portion of thepassage is in flow communication with the opening formed by the passages28, 30, 32, 34 in the root of the rotor blade. These passages adapt theroot to receive the laser blocking material from the injection moldingmachine.

The first jaw 92 of the tool 12 is shown in phantom. The lever 112 hasan end portion 112 a (shown in phantom) which engages the first jaw. Thelever has an adjustable link 112 b which allows for adjustment of thelength of the lever. The second jaw 94 (shown in phantom) is spaced fromthe first jaw by a small gap G in the operative closed condition. Thisgap is typically small and in one embodiment is less than twenty five tothirty mils (0.025-0.030 inches).

FIG. 3 is an exploded view, partially broken away, showing part of thetool 12 and part of the nozzle 70 of the injection molding machine 54.The tool includes the fixture 56. The fixture includes the tool base 58,the sprue plate 62, and the sprue plate holder 64. The sprue plateholder has an opening 119. The nozzle 70 extends through the opening 119to engage the sprue plate 62. The nozzle is pressed against the firstsurface 116 of the first side 114 by bolts (not shown) which urge thenozzle and sprue plate together. The sprue plate 62 has a second side120 having a second spanwise facing surface 122.

The fixture 56 also includes a member, as represented by a block 124(locating block), which is spaced spanwise from the sprue plate. Thelocating block 124 has a first reference surface 126 which faces in thespanwise direction and which engages the tip 18 of the airfoil 10 in theoperative condition. The locating block is formed of a material that issofter than the tip of the airfoil to avoid damaging the tip of theairfoil. The second mask member is adapted by a first opening 128 toreceive the block of material. As shown, the locating block is nested(put snugly inside) the second mask member 84 and helps the second jawlocate the second mask member.

The tool base 58 has a surface 132. The first mask member 82 and secondmask member 84 rest on the surface 132. The tool base has a locatinghole 134 and a base reference surface 136 bounding the bottom of thehole for positioning the locating block 124. The locating block isdisposed in the circular hole in the tool base to precisely locate theblock of material with respect to the tool base of the fixture. In analternate embodiment, the tool base might be the member having the firstreference surface 126 for engaging the tip of the airfoil and would usethe base reference surface 136 for this purpose.

The second mask member 128 has a second opening 138 which conforms to anaerodynamic edge of the airfoil, such as the leading edge 22 of theairfoil. The second mask member overlaps the leading edge of the airfoilon both the suction side 42 and the pressure side 44 of the airfoil.This engagement aids the mask in supporting and positioning the airfoilas the mask members are moved relative one to the other and moved intoengagement with the airfoil. In an alternate embodiment, the mask mightoverlap both edges or only the trailing edge 24 of the airfoil.

FIG. 3A is an alternate embodiment of the fixture shown in FIG. 3 havinga mask 78 a. The mask 78 a has a first mask member 82 a and a secondmask member 84 a. The mask 78 a may be formed with a pliant material atthe faying surfaces of the airfoil, such as a liner 78 b, in combinationwith a reasonably rigid support 78 c of material of the type used forthe locating block 124. Each mask member has a portion of the firstreference surface 126 a that engages a spanwise facing surface 17 on theairfoil. As shown, the spanwise facing surface 17 is on the platform 16a of the airfoil. The surface is similar to the spanwise facing surfaceof the second end or tip 18 of the airfoil in that the surface 16 a isadapted to engage the first reference 126 a of locating block 124 toposition the airfoil in the spanwise direction.

FIG. 4 is a perspective view from below of the sprue plate 62. Thesecond spanwise facing surface 122 has an area A1. The second surfacefaces spanwise toward the rotor blade in the operative condition. Thesecond side 120 has a projection 142 which extends in the spanwisedirection a distance D which is about sixty (60) mils. The projectionextends around the passage 65 to provide a bounded perimeter about thepassage. The projection further has a third surface 144 that providesanother (second) reference surface that faces in the spanwise directionfor engaging the airfoil. The third surface (second spanwise facingreference surface) has a spanwise facing area A2 which is less than thearea A1 (A2<A1).

The area A2 provides a sealing area or seal surface to the sprue plate.The third surface 144 having the area A2 (second spanwise facingreference surface) has a surface finish corresponding to a smoothmachine finish with a surface roughness Ra measurement of about sixtythree (63) micro inches as measured in accordance with the proceduresset forth in specification “ANSI B46.1-1985 Surface Texture” availablefrom the American National Standards Institute showing measurements asan average from the mean. The rotor blade has a surface having a finishcorresponding to a fine machine finish with a surface roughness finishRa of about one hundred and twenty five (125) micro inches.

The sprue plate holder 64 is integrally attached to the injectionmachine such as by fastening means or bonding. The sprue plate 62 isfixed to the sprue plate holder by a set screw or other device forfixing the holder to the plate. In the embodiment shown, fastening means(not shown) urge the sprue plate holder 64 toward the housing 68 of theinjection molding machine 54 and the sprue plate holder urges the sprueplate upwardly against the nozzle 70. In the operative condition, thesprue plate and the nozzle 70 of the injection machine are pressedtogether tight enough to form a seal to block the loss of laser blockingmaterial from the passage 65. The housing of the injection machinepushes downwardly on the sprue plate holder 62 with a force F of aboutone hundred pounds (100 lbf). This pushes the other side of the sprueplate against the airfoil to form a seal (at the interface between thereduced area A1 and the root of the airfoil). The force F is transmittedthrough the airfoil and presses the airfoil tip (second end) against theblock 124, trapping the airfoil spanwise between the block and the sprueplate.

In an alternate embodiment, the nozzle might press against the sprueplate and that force would urge the sprue plate against the root 14(second end) of the airfoil. Again, this forms a seal between the sprueplate and the airfoil at the second spanwise facing reference surface144 of the sprue plate and the root.

As mentioned, the locating block surface 126 (first reference surface)is softer than the tip of the rotor blade so that the tip 18 of therotor blade is not injured as the injection molding machine presses theairfoil against the block. Under operative conditions, the pressurizedmaterial exits the nozzle at a pressure of about sixteen hundred poundsper square inch (1600 psi) and a temperature of about three hundreddegrees Fahrenheit (300° F.).

FIG. 5 is an alternate embodiment 62 b of the sprue plate 62 shown inFIG. 4. The sprue plate 62 b is formed of a hardened two part epoxyavailable from the Ciba-Geigy Corporation., 4917 Dawn Avenue, EastLansing, Mich. 48823-5691. The material is supplied as R4036 resin withan R1500 hardener. This is one example of a suitable material for thelocating block 124.

The sprue plate 62 b shown in FIG. 5 has a recess 146 for receiving theroot 14 of the rotor blade. The recess has a seal surface 147 whichadapts the sprue plate 62 b to receive a polytetrafluoroethylene seal.The polytetrafluoroethylene seal is urged tightly against the sprueplate and against the rotor blade by the injection molding machine. Thepolytetrafluoroethylene seal has an opening 152 for passing the laserblocking material along the passage 65 from the sprue plate to the rotorblade. In one embodiment, the seal is about three fourths of inch longand one-half of an inch wide with an opening suitable for flowing theblocking material into the root of the airfoil. One satisfactorymaterial for the seal is mechanical grade Teflon® material which has avery small tendency to cold flow. This material is provided in sheetform by Interplast, Inc., One Connecticut Drive, Burlington, N.J.08016-4101. Interplast is a processor of Dupont Teflon® material.

The fixture 56 may be used in the process for orienting airfoil 10 withrespect to any machine for injecting laser blocking material, such asthe injection molding machine 54. One method for orienting a new airfoilwith respect to the injection machine so that like airfoils may berepetitively filled using the tool 12. The first step is to remove thetool 12 from the machine and to install the tool in an apparatus 154 asshown in FIG. 6. The apparatus has a table 156, similar to the table 66shown for the injection molding machine. The table has locating pins(not shown) which locate the tool in a predetermined relationship to thetable. The base of the tool has the locating hole 134 for positioningthe locating block 124. The locating block engages the tip of theairfoil with the first reference surface. The combination of the tool 12and table 158 locate the locating block in a known position with respectto the apparatus so that the tip 18 (second end) of the airfoil ispositioned with respect to the apparatus. Airfoils of different lengthare easily accommodated in the fixture changing the block to a blockhaving a suitable height.

The apparatus has a vertical member 154 having a groove 158. Theapparatus has a laterally extending plate 164. The plate has a verticalsupport 164 which slidably engages the groove. The plate is integrallyattached to the vertical support and is adjustable with respect to thevertical member by means of a locking clamp 166. In the embodimentshown, the apparatus plate is adapted to engage the sprue plate holder64 to locate the sprue plate holder and sprue plate 62 precisely in thespanwise direction with respect to the first reference surface 126 ofthe locating block and with the same relationship to the first referencesurface in the spanwise direction as in the operative condition.

A device, such as a sprue plate element, simulating the sprue plate 62might be used in place of the sprue plate as long as the device providesthe correct orientation of the root (first end) 14 of the airfoil to thefirst reference surface. The sprue plate element and the sprue plate areeach represented by the sprue plate 62 shown in FIG. 6. The advantage ofusing the sprue plate and the sprue plate holder or a device simulatingthe sprue plate holder is that it reproduces the engagement of sprueplate in the operative condition to the airfoil and to the other partsof the tool.

The method for orienting the airfoil 10 with respect to the injectionmolding machine 54 includes forming the fixture so that it has thecavity 13. The cavity adapts the fixture to receive the elastomeric maskmembers 82, 84 of the mask 78 for engaging the airfoil in the operativecondition.

The method includes forming the mask 78 for engaging the airfoil. Thisincludes the steps of forming a core having an airfoil portion which isdimensionally equivalent to the airfoil which is to be filled, at leastover that region of the core which engages the mask. Alternatively, anactual airfoil might be used for the core. After disposing the core inthe cavity, the plate 164 of the apparatus and the sprue plate 114 areadjusted to orient the sprue plate with respect to the airfoil, to thefixed second jaw 94, and to the first reference surface 126 on thelocating block 124. This method includes trapping the core between thesprue plate and the first reference surface such that the orientation ofthe core to the sprue plate and the core to the first reference surfaceis the same as in the operative condition.

The method includes disposing a masking material in fluid form in thecavity 13 and allowing the material to harden. One satisfactory materialis an elastomeric material such as room temperature, vulcanized materialavailable as R668 from the General Electric Company.

As shown in FIG. 2, the first jaw 92 and the second jaw 94 each have apair of spanwise extending grooves as represented by the grooves 174 a,174 b and the grooves 176 a, 176 b. The masking material flows intothese grooves. This material hardens to form strips on the mask. Thestrips are represented by the strips 178 a, 178 b which engage thegrooves 174 a, 174 b of the first jaw and the strips 182 a, 182 b whichengage the grooves 176 a, 176 b of the second jaw. The strips extend inthe grooves and engage the jaws in a chordwise direction substantiallyperpendicular to the surfaces of the jaws.

After the material hardens, the step of forming the mask 78 includescutting the masking material in a generally spanwise direction to form asingle parting line if a one piece mask is desired or two parting linesif a two-piece mask is desired. The parting line enables removal of thecore and insertion of the airfoil in the operative condition.

In the embodiment shown in FIG. 6, two parting lines are made on eitherside of the airfoil to divide the masking member into the pair of maskmembers 82, 84. In alternate embodiments, it might be desirable to havemore than a pair of mask members. The mask members are cut such thateach parting line extends between the cooling air holes of the finallymanufactured airfoil. This enables the mask to block the flow ofblocking material out of the holes 46 of the airfoil to such an extentthat the material does not flow to locating surfaces on the airfoil forthe laser drilling operation. This is important in those cases where arepaired airfoil is being redrilled or a newly manufactured airfoil isbeing reworked and the airfoil already has some cooling holes 46 formedin the surface of the airfoil.

The jaws 92, 94 of the tool are movable relative to each other. Themethod of orienting the airfoil by forming the mask includes spacing thejaws one from the other by the gap G in the closed position. (The gap Gis the distance that the jaws are spaced in the operative condition.) Alayer of molding material is disposed between the jaws to fill the gapG. The molding material seals the mold against the loss of maskingmaterial in fluid form. One satisfactory material is beeswax.Alternatively, the jaws might be spaced apart by a gap G1 which isgreater than the gap G. This might be achieved during the step offorming the mask by not fully closing the jaws. This results in thelateral length of the mask being slightly greater than the lateral widthof the cavity in the operative condition. The jaws under operativeconditions will then exert a predetermined level of force on the maskingmember. The same effect might be achieved by adjusting the length of thelever which moves the jaw. This might be done by employing an adjustablelink 112 b so that the jaws move to the fully closed position with a gapG in the operative condition but are adjusted so that the jaws arespaced apart by the gap G1. One satisfactory gap G1 was set at about oneeighth of an inch (125 mils). The gap G1 for the tool in the closedposition in one embodiment was about four times of the gap G for thetool in the operative condition.

A particular advantage of the tool 12 is the second jaw 94 which doesnot move. That jaw and the second chordwise facing reference surface 96have a predetermined relationship with respect to the locating hole 134because both are fixed. The locating hole positions, in turn, thelocating block 124 having the first reference surface 126. These knownrelationships cause the mask 78 and its mask members 82, 84 which engagethe jaw to have a known relationship with respect to the airfoil (whichengages the first reference surface) and the airfoil to the referencesurface on the second jaw 96; and, the airfoil and the mask to the sprueplate 62 through the second jaw and the base of the fixture and thencethrough the table of the apparatus to the housing 62. A small lateraladjustment might be required, for example, in the operative condition,depending on the size of gap G1 as compared to the gap G, to ensure thatthese components have the correct relationship in the operativecondition. Thus, this relationship in the apparatus fro making the maskis the same or very easily adjustable to the same relationship as in theoperative condition.

Certain thermoplastic polymers have characteristics which aid indisposing the laser blocking material 52 on the interior of the rotorblade 12 and in attenuating the intensity of the laser beam. Thesecharacteristics provide advantages during filling and drilling of theairfoil with a laser and advantages later as the blocking material isremoved from the airfoil. For example, the laser blocking materialcomprises a thermoplastic polymer formed of only carbon and hydrogen.The thermoplastic polymer creates harmless products on completecombustion of the material during burnout of the material. The polymeralso has a Melt Flow Index which is greater than about fifty (50) whichpromotes flow. The thermoplastic polymer is partially amorphous; but itis also partially crystalline such that the crystallinity is greaterthan forty percent (40%) to diffuse the beam of radiation from thelaser.

Experiments have been performed using members of the polyolefin family.The term “polyolefin” and the particular forms of the polyolefins suchas “polypropylene”, “polyethylene”, etc. include their copolymers andhomopolymers. For example, these include linear low density polyethylene(LLDPE), low density polyethylene (LDPE), high density polyethylene(HDPE), polypropylene (PP).

One satisfactory material is a linear, low-density polyethyleneavailable as Dowlex 2503 from the General Polymer Division of AshlandChemical Company and is manufactured by the Dow Chemical Company,Midland, Mich. 48674. This polyethylene has a specific gravity of ninehundred and thirty seven thousandths (0.9370) at twenty three degreesCelsius (23° C.) and a Melt Flow Index of one hundred and five (105)using the standard of measurement set forth in ASTM D-1238-82 entitled“Flow Rates of Thermoplastics by Extrusion Plastometer.” Melt Flow Indexis determined for this polyethylene by flowing a number of grams of thepolymer during a ten minute period through a known orifice at atemperature of one hundred and ninety degrees Celsius (190° C.) andunder a load of about two and sixteen hundredths Kilograms (2.16 kg)which correspond to condition E of the ASTM standard. This polyethylenehas an elongation at break of seventy five and two tenths percent(75.2%), a flexural modulus of seventy five thousand five hundred poundsper square inch (75500 psi), a tensile strength at break of elevenhundred pounds per square inch (1100 psi) and a tensile strength atyield of two thousand and ten pounds per square inch (2010 psi). Thenotched Izod impact strength is forty five hundredths (0.45) at sixtyeight point two degrees Fahrenheit (68.2° F.) at one-hundred and twentyfive thousandths 0.1250 inches (ft-lbs./in). The tensile impact strengthis sixty two and four tenths (62.40 ft-lb./per square inch) at seventythree and two tenths degrees Fahrenheit (73.2° F.). The brittletemperature is thirty six degrees Fahrenheit (36° F.) and the VicatSoftening temperature is two hundred and twelve degrees Fahrenheit (212°F.). It is a copolymer of ethylene and Octene-1.

At temperatures over five hundred and seventy two degree Fahrenheit orthree hundred degrees Celsius (572° F. or 300° C.) the material willrelease highly combustible gases. The specific gravity is less than oneand may be even less than ninety five hundredths because it lies in arange of about eighty four hundredths to ninety seven hundredths (0.84to 0.97) showing the absence of fillers. It has a fairly high molecularweight which is greater than one thousand (1000) and is formed of onlycarbon and hydrogen.

Polyolefins such as polypropylene, polyethylene, polybutylene,polyisoprene have the advantage of shear thinning coupled with theirrelatively good Melt Flow Index. The Melt Flow Index is measured at lowshear conditions. As shearing of the polyethylene increases, theviscosity of the material precipitously decreases and may decrease asmuch as fifty percent (50%) or even greater amounts.

An advantage of using the injection molding machine for injecting thelaser blocking material is that the machine itself and through thepressure it exerts, causes shear thinning of the polyethylene prior tothe polyethylene reaching the chamber 12, causes shear thinning as itpasses through the nozzle 70 and causes shear thinning, if required, inthe internal passages of the airfoil 10.

Like Melt Flow Index, the shear thinning characteristic is anempirically defined parameter, critically influenced by the physicalproperties and molecular structure of the polymer and the conditions ofmeasurement. It is determined by using a capillary rheometer but theparameter is not commonly available for materials at all temperaturesand pressures because scientists and engineers have not focused on thecriticality of the parameter, for example, for filling components havingvery narrow passages.

FIG. 7 is a graphical representation of the shear thinningcharacteristic for Dowlex 2503 polyethylene material as determined overa range of shear rates at a temperature of three hundred andseventy-five degrees Fahrenheit (375° F.) by Applicant's Assignee. ASTMD3835, Capillary Rheometer Test was used.

As shown in FIG. 7, the viscosity decreases precipitously from aninitial value of about five hundred Pascal Seconds (500 PaS) at a shearrate of twenty per second to a value of less than two hundred PascalSeconds (200 PaS) at a shear rate of two thousand per second (2000/sec).This represents a decrease of more than fifty percent (50%) from amolasses like liquid at the lower shear rate to a water like liquid asthe material flows through the airfoil at shear rates much smaller thanthe shear rate of two-thousand per second (2000/sec).

As the material is flowed from small passages in the airfoil to largepassages in the airfoil, the viscosity will increase as the polymerchains experience a smaller shear rate. However, as the polymer flowsthrough the next smaller cross-sectional area, such as at the trailingedge, the material will once again shear thin because of the increasedshear rate. The material will experience a decrease in viscosity andthen will more easily flow through th smaller area. As the materialflows out of the airfoil, the pressure on the material and temperaturesof the material rapidly decreases, causing the material to experience aprecipitous increase in viscosity and not flow to locating surfaces onthe airfoil.

Accordingly, shear thinning is very helpful in filling modern airfoilswith laser blocking material 52. Typically, the volume of the charge 74of material injected into the airfoil is about five to ten percent (5%to 10%) greater than the internal volume of the airfoil to be filled toensure complete filling of that volume. This volume of material must beforced into the airfoil, forced through the airfoil, and, to someextent, forced out of the airfoil to ensure complete filling of theairfoil. And yet, the material must have sufficient viscosity such thatthe material does run through the airfoil to unwanted locations on theairfoil surface. As mentioned, it must solidify in place fairly rapidlyafter injection as it flows into, through and out of the airfoil.

During the filling operation of the airfoil 10, for example, thethermoplastic polymer is forced into the blade at an extrusion pressuregreater than about fifteen hundred pounds per square inch (1500 psi) andat a temperature at about or greater than three hundred degreesFahrenheit (300° F.). There is a decrease in viscosity due totemperature. The temperatures of the material are expected to rangebetween two hundred and fifty and five hundred and forty degreesFahrenheit (250° F.-540° F.) for most materials in the polyolefinfamily. This allows the material to flow with low viscosity through theairfoil with the temperature causing a decrease in viscosity and theshear thinning causing a further decrease in viscosity.

In one application using the Dowlex 2503 material, the polyethylene wasextruded at a pressure of sixteen hundred pounds per square inch (1600psi) into an airfoil having passages and orifices having a hydraulicdiameter which was less than forty (40) mils. In some applications, thepassages may have a hydraulic diameter which is less than thirty (30)and even less than twenty five (25) mils. It is expected that as thepolyethylene is flowed through the airfoil passages, further shearthinning takes place in the especially restricted regions of the airfoilsuch as the leading edge or the trailing edge region of the airfoil. Inthese regions, pedestals and small diameter holes retard movement of thematerial into cavities into which holes extending to the surface aredrilled. Nevertheless, these airfoils were successfully filled, in part,because of the shear thinning characteristic of the laser blockingmaterial in the airfoil. In other trials, the material was injected at apressure of about two thousand pounds per square inch (2000 psi) with atemperature of the material that was less than five hundred and fortydegrees Fahrenheit (540° F.) and that was in the range of about fourhundred degrees Fahrenheit to about five hundred degrees Fahrenheit(400° F. to 500° F.). Polypropylene was also used with good results atsimilar pressures and at temperatures above its melting point.

During filling of the airfoil, the airfoil is disposed in the mask 78with the masking members 82, 84 urged against the airfoil by the firstand second jaws 92, 94. As mentioned, the table or the lever might beadjusted slightly to accommodate any difference between the gap G andthe gap G1. The mask members apply an external pressure to the airfoilwhich blocks the loss of laser blocking material which might passthrough the flow directing surfaces of the airfoil to unwanted locationson the airfoil. The mask members also reinforce the thin wall of theairfoil (which in some cases may be as small as twenty (20) mils)against deflection as the high pressure polyethylene material flowsthrough the airfoil.

The laser blocking material flows quickly into the interior of theairfoil, with filling of even complex shapes taking less than one-minuteand some cases about thirty (30) seconds. A particular advantage is therelatively low melting temperature of the material. As a result, thethermal capacitance of the airfoil is such that it absorbs heat from thematerial without increasing in temperature by an amount which makeshandling difficult. In some trials, operators were able to handle theairfoils after filling with bare hands or with light gloves.

Even though the material loses heat to the adjacent metal in theairfoil, the material continues to flow until it fills those areas thatrequire the disposition of laser blocking material. Solidification ofthe material occurs rapidly as the material loses heat to the airfoil.As a result, the airfoil can then be moved to a new location even withshaking and without concern about the material liquefying.

Another advantage of the blocking material is the resiliency which itdemonstrates in solid form. This allows for easy inspection of holesdrilled by the laser to ensure that the laser has penetrated through tothe blocking material. For example, one way of inspecting a hole to makesure the hole has been drilled through the wall of the airfoil, is toprobe through the hole with a thin wire. The wire exhibits a differentresponse on contact with the resilient polyethylene material as comparedto the contact that it would have against a hard component, such as thematerial. In many cases, the laser blocking material has flowed into thehole to such an extent that visual inspection of the hole shows thepresence of polyethylene, thereby confirming the existence of a throughhole.

During the drilling of a hole with the laser beam L, the coherentradiation of the laser beam vaporizes a wall, of the airfoil, such asthe suction wall 42 or pressure wall 44, to form a cooling air hole 46.As the laser beam breaks through the wall on the interior of theairfoil, the laser beam strikes the polyolefin (polyethylene) materialdisposed on the interior of the airfoil.

The polyolefin blocking material is particularly effective at preventingthe laser beam from unacceptably damaging the walls on the interior ofthe airfoil. Although the phenomenon in not well understood, it isbelieved that the crystallinity of the polyolefins helps this process.It is also believed that the specific heat and melting point of thepolyethylene is such that a small portion of the polyethyleneimmediately forms a fluid, either in gaseous form or in the form of aliquid, upon being struck by the laser beam. If gas, the polyethylenegas is formed of carbon and hydrogen, a combustible mixture, but withthe no oxygen being supplied by the material (since the material itselfis formed of only carbon and hydrogen). This avoids the formation ofsooty particles.

The plasma of the vaporized polyethylene is transparent to the laserbeam to such an extent that it apparently does not degrade the abilityof the laser beam to finish the drilling of the hole. In addition, thefluid does not appear to degrade the formation of the hole and, in fact,moves into the hole and may enhance the ability of the laser to leave aclean hole without blocking of the hole as a result of splatter frommolten wall material of the airfoil being sucked into the hole.

Experimental drilling operations have shown a marked decrease in wallblockage at completion of the drilling operation. The percent blockedholes in one run decreased from about fifty percent to sixty percent(50% to 60%) to less than ten percent (10%). This decreases the need forrework of the airfoil and promotes even distribution of cooling air inthe finished article.

Another advantage of the polyethylene in laser drilling is believed tobe the amount of diffusion of the laser radiation that takes place foran incremental thickness of polyethylene material. It is believed thatit is greater than many other materials used for blocking laserradiation. This may be linked to the relatively high crystallinity ofpolyolefins which is greater than forty percent (40%) and for the Dowlexpolyethylene material, greater than sixty percent (60%). It is believedthat polyolefins are preferable to other polymers because of the MeltFlow Index which is greater than fifty (50) and the melting point whichis sufficiently high such that the large quantities of laser blockingmaterial are not completely melted by the laser beam. As a result, insome drilling operations an additional pulse of laser energy beyond thatexperienced using conventional wax fill is possible, which also helpsform a clean exit hole with minimal blocking by backscatter of theairfoil material.

It is possible to combine with the polyolefin small amounts of other ispolymers. One example is less than about five percent (5%) by weight ofthe other polymers as long as the other polymers do not degrade theperformance of the polyolefin and do not pose an environmental risk onburnout of the material.

The addition of these other polymers to the polyolefin, or evenadditional amounts of other material to the thermoplastic polymer, is aconcern because thermoplastic polymers formed of only carbon andhydrogen provide a significant advantage during removal of laserblocking material after the holes are drilled in the airfoil. One methodof removing the laser blocking material is to heat the laser blockingmaterial until it burns. One satisfactory temperature is about thirteenhundred (1300° F.) degrees Fahrenheit. A particular advantage of thepolyolefin family and particularly polyethylene is the polymer breaksdown to form a highly combustible gas which is very clean burning. Thecarbon and hydrogen of the polyethylene combine with oxygen from thecombustion atmosphere to form carbon dioxide and water vapor. Thisleaves behind a very clean airfoil that does not require furtherprocessing to remove contaminants from the interior of the airfoil. Inaddition, scrubbers for removing harmful gasses from the burnoutoperation are not required provided significant oxygen is present tocompletely combust the laser blocking material. Finally, burnoutprovides the advantage of not having to flow additional solvents intothe blade or to manipulate the blades.

In addition, the polyolefins have a relatively low melting temperature,particularly the polyethylenes. As the airfoil is heated to a highertemperature to remove the polyethylene by burning the polyethylene, thepolyethylene melts and runs out of orifices in the blade instead ofcontinuing to expand and place unwanted internal pressures on theairfoil.

Finally, the polyethylene has a resiliency characteristic prior tomelting that allows the material to deform upon being deflected underload. The polyethylene material expands prior to melting as it is heatedduring the burnout operation. Expansion of the solid polyethylenematerial causes the material to deform, and openings in the airfoil mayeven allow the material to extrude so that all forces generated bythermal expansion of the material are not transmitted to the walls ofthe airfoil. The relatively thin walls of the airfoil are not deflectedto an extent that would cause harmful residual stresses in the airfoilor failure of the airfoil during the burnout operation. In addition,burnout may be provided at a relatively low temperature to speedhandling or at higher temperatures to decrease processing time as longas the temperature does not degrade the performance of the alloy fromwhich the airfoil is made.

Although the invention has been shown and described with respect todetailed embodiments thereof, it should be understood by those skilledin the art that various changes in form and detail may be made withoutdeparting from the spirit and scope of the claimed invention

We claim:
 1. A method for disposing laser blocking material on theinterior of an airfoil for blocking a beam of radiation from a laserduring a laser drilling operation, the airfoil having passages at leastone of which has a hydraulic diameter which is less than about forty(40) mils, comprising: forming a charge of laser blocking material thathas a shear thinning characteristic that is greater than zero and thatis a thermoplastic polymer formed of only carbon and hydrogen which ispartially amorphous and partially crystalline such that thecrystallinity is greater than forty (40) percent to diffuse the beam ofradiation from the laser; disposing the laser blocking material in achamber having a nozzle; flowing the laser blocking material from thechamber into the airfoil and through the passages which includes thesteps of, forcing a portion of the laser blocking material through anozzle from the chamber of material such that at least a portion of thematerial experiences shear thinning prior to the material entering theairfoil; transferring energy to the laser blocking material to raise thetemperature of the laser blocking material above the melting point ofthe material prior to the material entering the airfoil; pressurizingthe laser blocking material to a pressure that causes additional shearthinning as the material flows through said passage having a hydraulicdiameter that is less than forty (40) mils; wherein shear thinning ofthe material decreases the viscosity of the laser blocking material asthe material flows through small passages in the airfoil, therebydecreasing the pressure differential along the passage and between theexterior and the interior of the passage and wherein the decrease inviscosity from pressure through shear thinning decreases the need todecrease viscosity by heating the laser blocking material.
 2. The methodof disposing a laser blocking material in an airfoil of claim 1 whereinthe step of forming a charge of laser blocking material includesdisposing a blocking material in the chamber that is a single polyolefinor mixture of polyolefins.
 3. The method of disposing a laser blockingmaterial in an airfoil of claim 2 wherein the step of disposing blockingmaterial in the chamber includes disposing a polyolefin selected fromthe group consisting of linear low density polyethylene (LLDPE), lowdensity polyethylene (LDPE), high density polyethylene (HDPE),polypropylene (PP) and wherein the step of transferring energy to thelaser blocking material raises the temperature of the material to atemperature which is greater than three hundred degrees Fahrenheit (300°F.).
 4. The method of disposing a laser blocking material in an airfoilof claim 1 wherein the step of transferring energy includes passing thematerial through an injection molding machine which step furtherincludes transferring heat to the material and shearing the material totransfer energy to the material.
 5. The method of disposing a laserblocking material in an airfoil of claim 1 wherein the step of flowingmaterial into the airfoil includes flowing material into the airfoilwherein the material has a temperature in a temperature range of abouttwo hundred and fifty degrees Fahrenheit (250° F.) to five hundreddegrees Fahrenheit (−500° F.).
 6. The method of disposing a laserblocking material in an airfoil of claim 2 wherein the step of formingthe charge of laser blocking material includes determining the internalvolume of the airfoil and forming a charge having a volume that isgreater than the internal volume of the airfoil.
 7. The method ofdisposing a laser blocking material in an airfoil of claim 6 wherein theairfoil further has locating surfaces on the exterior of the airfoil fororienting the airfoil during processing and wherein the step of forminga charge includes forming a charge having a volume which is about fivepercent larger than the internal volume of the airfoil and wherein thestep of forming laser blocking material into the airfoil includesflowing laser blocking material out of the airfoil but not flowing laserblocking material to locating surfaces on the airfoil used duringprocessing of the airfoil.